Back in 2015 when we had designed the Revo-Rack and were searching for a manufacturing partner to help us develop the complex frame design, that Antony our CEO came up with ! We turned to Southern Europe know for its artisan design led manufacture. We visited several potential suppliers and 10 years on are so glad we partnered with who we did.
A small ish family firm established in 1969, with the business side now run by the founders daughter and the manufacture by his son, the attention to detail and care these guys put into every Revo-Rack frame blows us away every time we visit.
The Revo-Rack luggage rack frame manufacture process :
- The process starts with the bending of the external frame in super light 25mm 1" T5 aluminium tubing on the lastest CNC tube benders, the 8mm holes for the cups are drilled on the same machine !
- The frame is then welded together by hand, welding aluminium is a skilled job.
- Laser cut cross rail tubes are then welded into the frame again by hand
- The frame is then either powder coated black or hand polished and then anodised to create a mirror like shine, this is a very labour intensive process and accounts for the large price difference between the two frames.
- Each frame is inspected by hand for imperfections before it's shipped to us in a protective foam envelope.
Our partner suggested a number of improvements to our initial designs below
The laser cut end of a cross rail thats been hand polished and anodised before final assembly laid across a bare untreated frame
Revo-Racks frame are made with great care, using the latest CNC machines. The final frame weights only 1.7KG/3.5lbs due to its super light T5 Aluminium and Magnesium alloy tube.
The weld joining the two ends of the external frame together, this is then ground off to become invisible on the black frame and the weld leaves a trace thats hidden under a sticker on the PA frame